Monolithic slab floor construction



I Dec. 13, 1938. y H, A. FABER y 2,140,283

. IIII NTOR Hyerberr A. F ber l Hls AL .ORNEY Dec.A 13', 1938.

H. A. FABER MONOLI-THIC SLAB FLOOR CONSTRUCTION 2 Sheets-Sheet 2 FiledNov. 2l, 1936 lNvENT'oR erber A. Faber Hl ,ATTORNEY Patented Dec. 13,1938 UNITED STATES PATENT OFFICE 6 Claims.

My invention relates to floor construction, and more particularly to amonolithic slab floor embodying a network of structural members.

lThe invention has as its principal objects the provision of oorconstruction, that:

1. Combines unusual lightness with adequate load supportingcharacteristics for all ordinary purposes,

2. s of monolithic slab formation.

3. Has incorporated therein a network of structural members which initself affords support for floor loads.

4; Transmits the floor loads to contiguous walls along definitelydefined truss members, and distributes such loads between all of thewalls.

5. Is capable of construction on the job directly and completely fromraw materials, or partially from 'prefabricated structural elements.

6. Is capable of simple and economical construction.

The structural network providing the skeleton of the monolithic slablicor may be fabricated according to a variety of general methodsdependent upon the characteristics desired in the particular embodimentof floor construction. The type of material available at an advantageousprice, the labor factor involved, and the particular structuralcharacteristics desired for the floor will determine in any giveninstance the general type of structural network employed.

According to one of the herein described embodiments of floorconstruction pursuant to the present invention, a number of steelreinforcing rods or the like of suitable standard dimensions areassembled in three dimensional formation on the job, and are welded atjuncture points to provide an integral reinforcing network characterizedby truss formation extending longitudinally, latitudinally anddiagonally of rthe floor for transmission of loads to all of thecontiguous walls of the structure concerned.

According to another embodiment of floor construction pursuant to thepresent invention, a plurality of prefabricated structural elements arealigned side by side, adjacent elements being rigidly secured to eachother, and the resulting network being further rigidly tied together bymeans of additional elements extending transverse to the length of Athefirst stated elements and being secured thereto. The prefabricatedstructural elements are desirably stamped from sheet metal and bent tofinal configuration forming a plurality of trusses extending laterallyin integral 55 sequence. The stated transverse elements serve to retainthe prefabricated structural elements in truss formation.

Preferably a light weight composition material having self-adheringcharacteristics is utilized as a filler for surrounding and almostcompletely 5 covering the structural network in providing a monolithicslab. Any desired floor finishing composition may be applied to completeformation of the slab. The composition material functions necessarilyonly in the capacity of a ller. The 10 structural network in itselfsupports and distributes oor loads.

The composition material, however, does add to the strength of theresulting construction by stiffening the structural network. It also eec15 tively overcomes the tendency of the network to transmit sound.

In the drawings:

Fig. 1 illustrates in top perspective a portion of a skeleton net-workof structural members ac- 20 cording to one lpreferred form of theinvention preparatory to filling to slab status by composition material;

Fig. 2 represents a vertical section taken through a fragmentary endportion of a completed 25 floor construction pursuant to the form of theinvention illustrated in Fig, 1;

Fig. 3 represents a vertical section taken through a fragmentary endportion of a partially completed floor construction pursuant to another30 form of the invention. The section is taken on the line 3-3, Fig. 4;

Fig. 4 represents a vertical section taken on the line 4 4, Fig. 3;

Fig. 5 illustrates in top perspective prefabri- 35 cated structuralelements preparatory to assembly into the reinforcing network of theform of the invention illustrated in Figs. 3 and 4.

Referring to the drawings and particularly to Figs. 1 and 2, thereof:

Illustrated in Fig. 1 is a fragmentary portion of an assembledstructural network preparatory to filling by a composition material.

The illustrated network is preferably fabricated on the job fromstructural steel reinforcing rods or the like of any suitable standardsize. It may comprise an upper reticular layer l0 desirably havingsquare meshes and a lower reticular layer l l also desirably havingsquare meshes similar in dimension to the meshes of the reticular layerI 0. The two reticular layers are spaced apart from each other adistance approximating the desired thickness of the finished floor slab,and are disposed relative to each other such that the locations ofjuncture, see I2, of rods or the like of one 56 layer are respectivelypositioned substantially centrally of a mesh of the other layer.

In practice the meshes may be dimensioned to suit the particular` need.A satisfactory floor for general purposes is had by making each meshsquare and approximately 8 inches to a side, and spacing the upper andlower reticular layers Il) and II, respectively, approximately 8 inchesapart.

From each juncture location, 12, intermediate shear-rods I3, or thelike, are run to the four corners of the mesh upperly or lowerlythereof, and are rigidly secured at their ends, as for instance, bywelding, to the respective upper and lower reticular layers at locationsof intersection therein.

Accordingly, a rigid 3 dimensional structural network is formedcomprising trusses extending latitudinally, as at I4, longitudinally asat I5, and diagonally as at IE, throughout the extent of the floorconstruction, the trusses terminating and being supported at closelyspaced locations around the periphery of the oor. Channel elements II,Fig. 2, may be rigidly secured at locations of truss termination, i. e.,around the periphery of the network, and in turn may be secured to thewalls of the structure concerned in any suitable conventional manner.

The floor is brought to monolithic slab status by completely surroundingthe skeleton structural network, including filling of the intersticesthereof, with a composition filler material. This may be accomplished byerecting a temporary shoring below the network, or by suspending a sheetof plywood or the like from the network,

and-nlling to the desired level from above.

A light weight porous composition material I8, as for instance a mixtureof gypsum and sawdust, advantageously provides the main body of theslab. It desirably extends below the structural network a shortdistance, say one-half inch, `for providing a smooth nish surface andadding rigidity to the lower reticular layer II. The material I3preferably lls the structural network to a point short of the topreticular layer I 0, and a composition material I9, such as concrete forproviding a hard finish flooring is added to complete formation of theslab.

The structural network acts in itself as the supportV for floor loads,and transmits same through the trusses I3, I4 and I5 to all of thecontiguous walls of the structure concerned. The composition fillingmaterialV I8 and I9 serves to give body to the floor in effectingformation of the monolithic slab, and enhances in some degree thestrength-of the complete structure as well as overcoming the tendency ofthe network to transmit sound. The upper layer of concrete or the likeincreases the compressive strength of the structure.

Referring now to Figs. 3, 4 and 5, illustrating a floor construction,pursuant to another form of the present inventionat 25, see Fig. 5, areillustrated prefabricated structural elements employed in the assemblyofthe structural network.

The elements 25k are preferably stamped from sheet metal to provide setsof shear members 25a, extending in truss formation longitudinally of theblank. Advantageously there are three sets, 25-I, 25-2, and 25-3 ofshear members 25a defined longitudinally of the blank by solid stripportions 25h. The blank is bent along longitudinal lines to practicaltruss formation as illustrated, forming two V-shaped troughs having awall in common, and one being inverted with respect to the other. Thesolid strip portions 25?) become the tension and compression members ofthe resulting element 25.

Those tension and compression members 25D? forming the free lateral endsof the elements, indicated at A and B respectively, are congurated forinterlocking cooperation with like members of like elements. For thispurpose one of the stated tension or compression members, see A, is ofstraight flange formation, and the other, see B, is of channel flangeformation.

The elements 25 are assembled in side by side relation, the straightflange A of one element fitting into the channel flange B of theimmediately adjacent element. The flanges A and B of respectivecontiguous elements may be rigidly secured to each other in any suitablemanner, as for instance, by bolting, see 26, Figs. 3 and 4.

For maintaining the elements 25 in practical truss formation and foradding rigidity to the individual truss members, reinforcing stripelements 2'I are positioned transversely of the length of the associatedelements 25 in spaced preferably mutually parallel relation at the topand bottom thereof. They are secured to the elements 25 at locations ofintersection with the tension or compression members 25h'.

Advantageously the reinforcing strip elements 2 are in the form of sheetmetal channels. The walls of the channels are scored in suitableconfiguration at locations ofultimate intersection with the tension orcompression members 25h in a manner permitting outward bending ofopposite portions of the channel walls to provide receiving recesses 23at spaced intervals in the reinforcing strip elements adapted. for thereception of the respective tension and. compression `members 25h. Suchprovision of recesses 28 results in the formation of wing portions 21a,extending from opposite sides of the channel bottom and affordingextended contact area between. the reinforcing strip elements 21 and therespective tension and compression members 25h at locations of mutualintersection. Rigid securement of the reinforcing strip elements to thetruss elements at locations of mutual intersection may be accomplishedbythe aforesaid bolting indicated at 26.

The resulting skeleton network of structural elements is preferablyreinforced peripherally by an enclosing frame. Conveniently, anglestrips of sheet metal are rigidly secured along the top edge, see 2S,Fig. 4, and along the bottom edge, see 3B, Fig. 4, of the sides of thenetwork in which the trusses terminate. Channels of sheet metal,substantially coextensive in height with the height of the elements 25,may be secured, respectively,` as indicated at 3l, Fig. 3, to thelateral free edges A or B of the respective terminal elements 25 of theskeleton network to complete the enclosing frame.

Disposition of the skeleton network between walls of the structureconcerned may be accomplished in any suitable conventional manner. Thenetwork is filled to monolithic slab status in a manner similar to thatdescribed in reference to Figs. l and 2, a light weight compositionmaterial 32 providing the major portion of the slab and a comparativelyhard facing of concrete or like material 36 providing a floor facing.

It will be noted that the skeleton network, made up of prefabricatedelements 25, is comparatively light in weight by reason of its sheetmetal formation. Its inherent rigidity enhanced by the surrounding slabmaterial, provides. a floorV construction of light weight but ofconsiderable load supporting ability.

To give added rigidity to the prefabricated elements 25, and to enhancethe load supporting characteristics of the combination of elements, thelateral edges of the shear members 25a may be bent, preferably at rightangles to the body of the shear member, to provide lateral flanges (notillustrated) therefor; or any form of crimping suitable for the purposemay be employed. It is preferred to accomplish such bending or crimpingduring, and desirably as a part of, the cutting and stamping operation.

Whereas this invention has been described with reference to a particularform thereof, it is to be distinctly understood that a variety ofchanges may be made therein without departing from the spirit of theinvention as defined by the following claims.

I claim:

1. A oor construction comprising a monolithic slab of compositionmaterial having embedded therein a three dimensional network ofstructural members extending from end to end of the floor constructionand secured peripherally to contiguous walls of the structure concerned,said composition material comprising a light weight frangible massforming the body of the slab and a mass of heavier weight andcomparatively hard nish forming the floor surface of the slab.

2. In a building construction, a skeleton structure comprising aplurality of structural elements secured side by side and extendingsubstantially parallel lengthwise, said structural elements eachcomprising a plurality of sheet members parallel lengthwise andextending lat erally in integral sequence in alternate V and inverted Vconfiguration, the said sheet members being perforated to impart trussformation thereto and being sequentially interconnected by longitudinaltension and compression members, and strip elements extendingtransversely of said structural elements at spaced intervals along thetop and bottom thereof and secured thereto at locations of intersectionforming a three dimensional network of structural members, said skeletonstructure being completely embedded in composition material whichcomprises a mass of light weight frangible material.

3. A floor construction, comprising a monolithic slab of compositionmaterial having embedded therein a skeleton structure as recited inclaim 2, said composition material comprising a mass of light weightfrangible material forming the body of the slab and a mass of heavierweight and comparatively hard finish forming the floor surface of theslab.

4. A structure as recited in claim 2 wherein the strip elements are ofchannel formation, and portions of the flanges of such channel stripsare displaced at locations of intersection of the channel strips withthe structural elements to enable the webs of the channel strips to tflush against the V-vertices of the structural elements which theytraverse.

5, A three dimensional structural network comprising structural elementsassembled side by side sequentially, the said structural elements eachcomprising a sheet of metal bent to form two V-shaped troughs having awall in common and being disposed ooextensively lengthwise, one beinginverted with respect to the other, and the side walls of the V-shapedtroughs being perforated to impart truss formation thereto, saidassembly of structural elements. resulting in a series of alternateV-shaped and inverted V- shaped troughs, and channel shaped stripsextending transversely of the said V-shaped troughs at spaced intervalsalong the top and bottom of the said assembly of structural elements,portions of the flanges of said channel shaped'strips being displaced atlocations. of intersection thereof with the structural elements,enabling the webs of the channel shaped strips to fit flush against theV-vertices. of the structural elements for securement thereto.

6. A floor construction as recited in claim 1, wherein the light weightfrangible mass comprises a mixture of gypsum and sawdust.

HERBERT ALFRED FABER.

